Modular print engines and modular print engine components

ABSTRACT

Modular print engines and print engine components that are usable in desktop card printers for personalizing plastic cards such as financial cards including credit and debit cards, identification cards, driver&#39;s licenses, and other personalized plastic cards. The modular nature of the print engines and print engine components permit alteration in the specific functionality of the desktop card printers depending upon, for example, the personalization requirements of the plastic cards and intended applications of the desktop card printers. In addition, the modular print engine components can be completely tested prior to installation into the modular print engines to ensure that the modular print engine components are working correctly prior to installation. Furthermore, the modular print engine components add flexibility to the desktop card printers as upgraded functionality and features can be introduced by developing new modular components.

FIELD

This disclosure describes modular print engines and modular print enginecomponents that can be used with the modular print engines topersonalize plastic cards such as financial cards including credit anddebit cards, identification cards, driver's licenses, and otherpersonalized plastic cards.

BACKGROUND

Plastic cards such as financial cards including credit and debit cards,identification cards, driver's licenses, and other personalized plasticcards are typically personalized with personal information of theintended card holder. Examples of personalization include, but not arelimited to, names, addresses, photographs, account numbers, employeenumbers, or the like. The personal information may be applied to thecard in a number of different ways including, but not limited to,printing on a surface of the document, storing the information on amagnetic stripe disposed on the card, and storing the information on anintegrated circuit chip or smart chip embedded in the card.

In some cases, the plastic cards are personalized using a desktop cardprinter that has a relatively small footprint intended to permit thedesktop card printer to reside on a desktop and that is designed topersonalize cards in relatively small volumes, for example measured intens or low hundreds per hour. An example of a desktop printer is theCD800 Card Printer available from Entrust Datacard Corporation ofShakopee, Minn.

Desktop card printers are typically designed to be relatively small sothat the printers can fit onto a desk or table. The desktop card printermay be positioned on a support surface with other office machines andworkspace, so that table and desk space is at a premium. Therefore, theamount of desk or table space required for the desktop card printer(i.e., its “footprint”) should be minimized.

At the same time, it is desirable that a desktop card printer be able toperform multiple card processing operations, thereby increasing theperformance capability of the desktop card printer.

Additionally, desktop card printers should be easy to operate andmaintain with only a minimal amount of specialized training. Desktopcard printers are often operated by personnel for whom producing cardsis only an incidental portion of their job, such as a security guard ora desk clerk, and not by personnel who have special training in suchequipment. The operation and maintenance of the card printer should thusbe relatively intuitive and straightforward. Furthermore, the cards thatare output from the card printer must be of the highest quality,attractive, and durable.

SUMMARY

Modular print engines and modular print engine components useable withthe modular print engines are described. The modular print engines andprint engine components are usable in desktop card printers forpersonalizing, for example, plastic cards such as financial cardsincluding credit and debit cards, identification cards, driver'slicenses, and other personalized plastic cards. The modular nature ofthe print engines and print engine components described herein permitalteration in the specific functionality of the desktop card printersdepending upon, for example, the personalization requirements of theplastic cards and intended applications of the desktop card printers. Inaddition, the modular print engine components can be completely testedprior to installation into the modular print engines to ensure that themodular print engine components are working correctly prior toinstallation. Furthermore, the modular print engine components addflexibility to the desktop card printers as upgraded functionality andfeatures can be introduced by developing new modular components.

In one embodiment, the modular print engine can be removably mounted ontop of a lower module that performs one or more card processingoperations including, but not limited to, embossing, laminating, or bothembossing and laminating. The functionality of the desktop card printercan be selectively altered by installing different ones of the modularprint engine components into and/or onto the module print engine. Beforeor after printing in the modular print engine, a plastic card can bedirected from the modular print engine into the lower module to performthe processing operation(s) of the lower module. Thereafter, the plasticcard can be output from the lower module or directed back into themodular print engine for further processing and/or output of thepersonalized card.

The modular print engine can include a card input at a front end of ahousing, as well as a card input hopper which is in communication withthe card input to input cards into the modular print engine forpersonalization. A card reorienting mechanism is in the housing adjacentto a rear end thereof, and the card reorienting mechanism is configuredto receive a plastic card and rotate the card to redirect the card alonga desired card travel path in the housing. A first card travel pathextends between the card input and the card reorienting mechanism withcards being transported along the first card travel path by a cardtransport mechanism. A print engine that is configured to print on acard is disposed along the first card travel path. The print engine canperform any type of printing including, but not limited to, retransferprinting, direct to card printing, ink jet printing, laser marking,laser engraving, and any other type of printing performed on cards.

The modular print engine also includes a second card travel pathextending from the card reorienting mechanism. A removable option moduleis disposed along the second card travel path. The removable optionmodule includes at least one personalization mechanism that isconfigured to perform a personalization operation on a card. Theremovable option module can be removed and replaced with a differentoption module that is configured to have a different functionality. Aplurality of different option modules, each having differentfunctionality, can be created. Each option module is configured to beindividually and separately removably installed in the housing along thesecond card travel path, and each option module is configured to performa different personalization operation on a plastic card receivedthereby. One option module can be removed and replaced with a differentoption module to change the functionality of the modular print engine.

The modular print engine includes a first card opening in the bottom ofthe housing. A third card travel path extends from the card reorientingmechanism to the first card opening to permit a card to be output fromthe modular print engine and into the lower module. In some embodiments,after processing in the lower module, the plastic card can be input backinto the modular print engine through the first card opening for furtherprocessing and/or output from the modular print engine.

In one embodiment, a second card opening can be provided in the rear endof the housing, and a fourth card travel path extends from the cardreorienting mechanism to the second card opening. In this embodiment, asecond option module can be attached to the rear end of the housing forreceiving a card from the second card opening. The second option modulecan include at least one processing mechanism that is configured toperform a processing operation on a card.

In another embodiment, a second card opening can be provided in the topof the housing, and the second card travel path extends from the cardreorienting mechanism to the second card opening. An upper expansionmodule can be attached to the top of the housing and can receive aplastic card from the modular print engine through the second cardopening, with the card then being directed to an output of the upperexpansion module through which the plastic card can be output from theupper expansion module.

In one embodiment, a modular print engine useable in a desktop cardprinter that personalizes cards includes a housing having a front end, arear end, a top and a bottom. A card input is at the front end of thehousing, and a card input hopper is disposed at the front end of thehousing that is in communication with the card input. A card reorientingmechanism is disposed in the housing adjacent to the rear end, with thecard reorienting mechanism being configured to receive a card and rotatethe card to redirect the card along a desired card travel path. A firstcard travel path extends between the card input and the card reorientingmechanism. In addition, a second card travel path extends from the cardreorienting mechanism. A print engine that is configured to print on acard is disposed along either the first card travel path or the secondcard travel path, and a removable option module is disposed along eitherthe first card travel path or the second card travel path. The removableoption module includes at least one personalization mechanism that isconfigured to perform a personalization operation on a card. Inaddition, a first card opening is formed in the bottom of the housing,and a third card travel path extends from the card reorienting mechanismto the first card opening.

In another embodiment, a desktop card printer system that personalizescards includes a housing having a front end, a rear end, a top and abottom. A card input is at the front end of the housing, and a cardinput hopper is in communication with the card input. A card reorientingmechanism is disposed in the housing adjacent to the rear end, with thecard reorienting mechanism being configured to receive a card and rotatethe card to redirect the card along a desired card travel path. A firstcard travel path extends between the card input and the card reorientingmechanism. In addition, a second card travel path extends from the cardreorienting mechanism. A print engine that is configured to print on acard is disposed along either the first card travel path or the secondcard travel path. The system also includes a plurality of optionmodules, where a single one of the option modules is configured to beremovably installed in the housing along either the first card travelpath or the second card travel path. Each option module is configured toperform a different personalization operation on a plastic card receivedthereby. Therefore, by changing the option module that is installed, thefunctionality of the desktop card printer can be changed.

As used herein, a processing mechanism is intended to encompass amechanism that performs a processing operation on a card that caninvolve personalization or not involve personalization. For example,applying a transparent protective laminate, perhaps even including ahologram or other non-personalized security feature, is an example of acard processing operation that does not involve personalization.Applying a name, address, photograph, account number, employee number,signature, or the like to a card are examples of processing operationsthat involve personalization. A personalization mechanism is intended toencompass a mechanism that performs a processing operation on a cardthat involves personalization. The term processing operation thereforeencompasses both personalization and non-personalization operationsperformed on a card, while the term personalization operationencompasses personalization operations performed on a card.

DRAWINGS

FIG. 1 schematically illustrates a modular print engine described hereinremovably mounted on top of a lower module.

FIG. 2 schematically illustrates an example of a re-transfer printengine that can be used with the modular print engine of FIG. 1.

FIGS. 3A-D schematically illustrate examples of different option modulesthat can be installed one at a time in the modular print engine of FIG.1.

FIG. 4 schematically illustrates another embodiment of a modular printengine with an upper expansion module.

FIG. 5 schematically illustrates another embodiment of a modular printengine with a second option, or rear expansion, module.

FIGS. 6A-C schematically illustrates examples of different second optionmodules that can be used with the modular print engine of FIG. 5.

FIG. 7 schematically illustrates another embodiment of a modular printengine with an option module located below the print engine.

FIG. 8 schematically illustrates another embodiment of a modular printengine with a removable option module located between the input and thecard reorienting mechanism.

DETAILED DESCRIPTION

As described further below, in some embodiments, a modular print engine10 can include a card reorienting mechanism that is disposed at theintersection of four distinct card travel paths. In one embodiment, thefour card travel paths are located at 90 degree intervals around thecard reorienting mechanism and the card travels paths extend eitherhorizontally or vertically. However, the four card travel paths can bepositioned at other spaced intervals about the card reorientingmechanism, and the card travel paths need not extend horizontally orvertically.

In addition, the modular print engine 10 described further below caninclude a card input at a front end thereof and a card opening through arear end thereof. In some embodiments, there can also be a card openingthrough a bottom of the modular print engine 10. In other embodiments,there can also be a card opening through a top of the modular printengine. Depending upon the desired card travel path through the desktopcard printer, the card openings can be card inputs or both inputs andoutputs.

Referring to FIG. 1, a first embodiment of a modular print engine 10 isillustrated as being detachably and removably mounted on top of a lowermodule 12. Together, the modular print engine 10 and the lower module 12form a desktop card printer that in use is configured to personalize,for example, plastic cards such as financial cards including credit anddebit cards, identification cards, driver's licenses, and otherpersonalized plastic cards. The desktop card printer is designed to havea relatively small horizontal (i.e. front to back) footprint intended topermit the desktop card printer to reside on a desktop or table and thatis designed to personalize cards in relatively small volumes, forexample measured in tens or low hundreds per hour.

The connection between the modular print engine 10 and the lower module12 can be any form of non-permanent connection that permits the modularprint engine 10 to be detachably mounted on top of the lower module 12and that permits the modular print engine 10 to be non-destructivelydetached from the lower module 12 without destroying any portion of themodular print engine 10 or the lower module 12. An example of a suitabledetachable mounting between a print engine and a lower module is thedetachable mounting used in the CD800 print engine that interfaces witha lower laminator module or the CE870 print engine that interfaces witha lower embosser module, both of which are available from EntrustDatacard Corporation of Shakopee, Minn.

The lower module 12 is of conventional construction and operation and asshown in FIG. 1 generally includes a lower module housing 14 illustratedin dashed lines with a front end 16, a rear end 18 opposite the frontend 16, a top 20, and a bottom 22 opposite the top 20. A main cardtransport path 24 is defined in the housing 14 along which a plasticcard is transported generally in a horizontal direction or generallyparallel to the top 20 and the bottom 22. A slot 26 is defined in thetop 20 of the housing 14 through which a card can be input into thehousing 14 from the modular print engine 10 and, in some embodiments,output from the housing 14 back into the modular print engine 10. Asecondary card transport path 28 leads from the slot 26 to a cardreorienting mechanism 30 that is disposed adjacent to the rear end 18 ofthe housing 14. In one embodiment, the secondary card transport path 28can be generally vertical or perpendicular to the main card transportpath 24 which can be generally horizontal.

The card reorienting mechanism 30 is rotatably disposed in the housing14 for rotation both clockwise and counterclockwise as indicated by thearrow on the card reorienting mechanism 30. When a card is being inputinto the lower module 12 from the modular print engine 10, the cardreorienting mechanism 30 is configured to receive a card along thesecondary card transport path 28 and rotate the card so as to direct thecard along the main transport path 24. Likewise, when a card is beingoutput from the lower module 12 back into the modular print engine 10,the card reorienting mechanism 30 can receive a card from the maintransport path 24, and rotate the card so as to direct the card alongthe secondary card transport path 28 for transport out of the lowermodule 12. Examples of suitable card reorienting mechanisms aredescribed in U.S. 2013/0220984 and U.S. Pat. No. 7,398,972 each of whichis incorporated herein by reference in its entirety. A card istransported along the main card transport path 24 and the secondary cardtransport path 28 by suitable card transport mechanisms, such as rollers32, 34. In some embodiments, the card transport mechanisms arereversible to allow a card to be transported in forward (i.e. duringcard input) and reverse (i.e. during card output back through the slot26) directions along each card transport path 24, 28 as shown by thearrows in FIG. 1. In other embodiments where the card is to be outputdirectly from the lower module 12 after processing in the lower module12, the card transport mechanisms need not be reversible.

The lower module 12 includes at least one card processing mechanism 36disposed along the main card transport path 24 that is configured toperform a processing operation on the card. In one embodiment, a singlecard processing mechanism 36 can be provided. In another embodiment, twoor more card processing mechanisms 36 can be provided one after theother along the main card transport path 24. Examples of card processingmechanisms 36 that can be used include, but are not limited to, a cardembosser or a card laminator. The lower module 12 can also include anoutput 38 at the end of the transport path 24 through which a card canbe output from the lower module 12 after processing by the processingmechanism(s) 36. In some embodiments, the lower module 12 may alsoinclude a card de-bowing mechanism (not shown) that is used to eliminatea bow that may occur on the card as a result of processing by theprocessing mechanism(s) 36. An example of a suitable de-bowing mechanismthat can be used is described in US 2014-0345787 the entire contents ofwhich are incorporated herein by reference. A suitable lower module witha card embosser or a card laminator is available from Entrust DatacardCorporation of Shakopee, Minn.

In operation of the lower module 12, a card enters the lower module 12from the modular print engine 10 through the slot 26. The card istransported along the secondary card transport path 28 and into the cardreorienting mechanism 30 which is then rotated to bring the card in linewith the main card transport path 24. The card is then directed alongthe main card transport path 24 to the card processing mechanism(s) 36which performs the one or more processing operations on the card. In oneembodiment, the card is then transported along the transport path 24 tothe output 38 and output from the lower module 12, for example into ahopper that can collect multiple cards. In other embodiments, afterprocessing by the card processing mechanism(s) 36, the card can betransported in the reverse direction along the main card transport path24 back to the card reorienting mechanism 30 which receives the card androtates the card to bring the card in line with the secondary cardtransport path 28. The card is then transported along the secondary cardtransport path 28 and back out of the lower module 12 through the slot26 and back into the modular print engine 10.

With continued reference to FIG. 1, the modular print engine 10 includesa housing 50 having a front end 52, a rear end 54, a top 56 and a bottom58. A main card input 60 is located at the front end 52 of the housing50 through which plastic cards to be processed by the modular printengine 10 and/or by the lower module 12 (i.e. processed by the desktopcard printer) are input. In some embodiments, the card input 60 can alsoform a card output through which processed cards can be output from themodular print engine 10. In other embodiments, a card output that isseparate from the card input 60, but also located at the front end 52like the card input 60, can be provided through which processed cardscan be output from the modular print engine 10.

A card input hopper 62 can be mounted at the front end 52 of the housing50 that is in communication with the card input 60. The card inputhopper 62 is designed to hold a number of plastic cards waiting to beprocessed which are fed one-by-one into the housing 50 by a suitablecard feed mechanism 64 known in the art. In embodiments where a cardoutput is also located at the front end 52, a card output hopper 66 canalso be mounted at the front end 52 of the housing 50 that is incommunication with the card output for receiving finished processedcards. The card output hopper 66 is designed to hold a number offinished processed cards after they have been processed which are fedout of the housing through a suitable card outlet, which can coincidewith or be separate from the card inlet 60, and dropped into the cardoutput hopper 66 in a manner known in the art. In one embodiment, thecard input hopper 62 and the card output hopper 66 form an integral,single unit where the input hopper 62 and the output hopper 66 arecombined together into a common structure that is mountable andremovable as a single unit from the housing 50. In another embodiment,the input hopper 62 (as well as the output hopper 66 or both the inputhopper 62 and the output hopper 66) can be configured with a multihopperconfiguration where the input hopper 62 is configured to simultaneouslyhold different card stock (for example, Visa® and Mastercard® brandedcard stock; driver's license card stock from different states;identification card stock having different security levels; etc.)waiting to be personalized. Each type of card stock can be selectivelyinput into the modular print engine from the input hopper 62 as selectedby the printer controller based on the type of card to be created.

A main or first card travel path 68 extends through the housing 50 fromthe input 60. In the illustrated example, the card travel path 68extends substantially horizontally through the housing 50 substantiallyparallel to the bottom 58. Cards are transported along the card travelpath 68 by a card transport mechanism, such as sets of rollers 70. Insome embodiments, the card transport mechanism can be reversible toallow the cards to be transported in forward (for example during cardinput or during printing) and reverse (for example, if a card is to beoutput from the modular print engine 10 through the front end 52 or totransport a card upstream of a printer before, during or after printing)directions along the travel path 68 as shown by the arrow in FIG. 1.

A card reorienting mechanism 72 is disposed in the housing 50 along thecard travel path 68 adjacent to the rear end 54. The card reorientingmechanism 72 is rotatably disposed in the housing 50 for rotation bothclockwise and counterclockwise as indicated by the arrow on the cardreorienting mechanism 72. The card reorienting mechanism 72 isconfigured to receive a card along the card travel path 68 and rotatethe card so as to direct the card in a different direction along adesired card travel path. Examples of suitable card reorientingmechanisms are described in U.S. 2013/0220984 and U.S. Pat. No.7,398,972 each of which is incorporated herein by reference in itsentirety.

A print engine 74 is disposed along the card travel path 68 that isconfigured to print on a card disposed on the card travel path 68. Inone embodiment, the print engine 74 can be configured to performretransfer printing as described further below with respect to FIG. 2.However, the print engine 74 can be configured to perform direct to cardprinting, ink jet printing, laser marking, laser engraving, and anyother type of printing performed on cards.

With continued reference to FIG. 1, a second card travel path 76 canextend upwardly from the card reorienting mechanism 72. In oneembodiment, the second card travel path 76 extends substantiallyvertically upward from the card reorienting mechanism 72. However, thesecond card travel path 76 is not limited to extending vertically andcan instead extend upwardly at an angle to vertical. Cards aretransported along the card travel path 76 by a card transport mechanism,such as sets of rollers 78. In some embodiments, the card transportmechanism can be reversible to allow the cards to be transported inforward and reverse directions along the travel path 76 as shown by thearrow in FIG. 1.

A removable option module 80 is disposed along the second card travelpath 76 and above the first card travel path 68. The removable optionmodule 80 includes at least one card processing mechanism that isconfigured to perform a processing operation on a plastic card. Asdiscussed further below with respect to FIGS. 3A-D, the removable optionmodule 80 is one of a plurality of removable option modules 80 that canbe installed one at a time in the modular print engine 10 to permitchanges to the functionality of the modular print engine 10. Each optionmodule 80 is configured to be individually and separately removablyinstalled in the housing 50 along the second card travel path 76 andabove the first card travel path 68, and each option module 80 isconfigured to perform a different processing operation on a plastic cardreceived thereby. One option module 80 can be removed and replaced witha different option module 80 to change the functionality of the modularprint engine 10.

FIG. 3A illustrates that in one embodiment, the option module 80 caninclude a magnetic stripe reader and/or writer 82 that can read data ona magnetic stripe of a card and/or write data onto the magnetic stripe.Magnetic stripe readers and/or writers are well known in the art. FIG.3B illustrates that in another embodiment, the option module 80 caninclude a smart card reader and/or writer 84 that can read data storedon an integrated circuit chip (i.e. smart card chip) on the card and/orwrite data to the chip. The smart card reader and/or writer 84 can beconfigured for contact or contactless reading and/or writing. Smart cardreaders and/or writers, both contact and contactless, are well known inthe art. In another embodiment illustrated in FIG. 3C, the option module80 can include both the magnetic stripe reader and/or writer 82 and thesmart card reader and/or writer 84 arranged in any order. In anotherembodiment illustrated in FIG. 3D, the option module 80 can include twosmart card readers and/or writers 84. The card processing mechanism(s)in the option modules 80 is not limited to a magnetic stripe readerand/or writer 82 and a smart card reader and/or writer 84. Other cardprocessing mechanisms can be included in the option modules 80 incombination with or separately from the magnetic stripe reader and/orwriter 82 and the smart card reader and/or writer 84. Examples of othercard processing mechanisms that can be included in the option modules 80can include, but are not limited to, a scanner that can read a onedimensional bar code on a card surface, a camera that can be used toread a one or two dimensional bar code on a card surface or capture animage of a card surface, a hole puncher that punches one or more holesin the card, and other card processing mechanisms. In one embodiment,the camera, if used, can be arranged to capture one or more images of acard surface while the card is held by the card reorienting mechanism72.

Depending upon the desired functionality of the modular print engine 10,one can install the appropriate option module 80 in the modular printengine 10. Because each option module 80 is modular, each option module80 can be completely tested prior to installation into the modular printengine 10 to ensure that the option module 80 is working correctly priorto installation. Further, to change functionality of the modular printengine 10, the user can replace one option module 80 with another optionmodule 80 having the desired functionality.

Returning to FIG. 1, a third card travel path 86 can extend downwardlyfrom the card reorienting mechanism 72. In one embodiment, the thirdcard travel path 86 extends substantially vertically downward from thecard reorienting mechanism 72 substantially in-line with the card travelpath 76. However, the third card travel path 86 is not limited toextending vertically and can instead extend downwardly at an angle tovertical. Cards are transported along the card travel path 86 by a cardtransport mechanism, such as rollers 88. In some embodiments, the cardtransport mechanism can be reversible to allow the cards to betransported in forward and reverse directions along the travel path 86as shown by the arrow in FIG. 1.

The third card travel path 86 extends to a card opening 90 in the bottom58 of the housing 50. When the modular print engine 10 is correctlymounted on the lower module 12, the third card travel path 86 and thecard opening 90 are aligned with the card transport path 28 and the slot26 of the lower module 12 so that a card can be transferred between themodular print engine 10 and the lower module 12, i.e. transferred out ofthe modular print engine 10 and into the lower module 12, and in someembodiments, transferred out of the lower module 12 and back into themodular print engine 10.

In some embodiments, the modular print engine 10 can further include afourth card travel path 92 that can extend rearwardly from the cardreorienting mechanism 72 as discussed further below with respect to FIG.5. In one embodiment, the fourth card travel path 92 can extendsubstantially horizontally from the card reorienting mechanism 72in-line with the card travel path 68. However, the fourth card travelpath 92 is not limited to extending horizontally and can instead extendat an angle to horizontal. When the fourth card travel path 92 ispresent, the travel path 92 extends to a card opening 94 formed in therear 54 of the housing 50 to permit cards to exit and enter the cardopening 94 through the rear 54 of the housing 50.

The modular print engine 10 can therefore include a card input at thefront end 52 thereof and the card opening 94 through the rear 54thereof. In some embodiments, there can also be the card opening 90through the bottom of the modular print engine 10. In other embodiments,there can also be the card opening 202 discussed in FIG. 4.

Returning to FIG. 1, in some embodiments a card de-bowing mechanism 100can be provided in the travel path 68 after the print engine 74. Thede-bowing mechanism 100 is configured to bend the card after printing toremove a bend in the card that may develop as a result of the printingof the card, especially with retransfer printing. The de-bowingmechanism 100 can be any mechanism that is suitable for eliminating abend that may develop in the card. An example of a suitable de-bowingmechanism 100 that can be used is described in US 2014-0345787 theentire contents of which are incorporated herein by reference.

A card reject hopper 102 is also located in the modular print engine 10,for example above the travel path 68, above the de-bowing mechanism 100,and adjacent to the card reorienting mechanism 72. The card rejecthopper 102 is positioned to receive cards that one may wish to store andnot output from the modular print engine 10, for example cards that aredetermined to be defective for some reason. For example, a card may bedetermined to be defective by failing to read and/or write data usingthe magnetic stripe reader and/or writer 82 or using the smart cardreader and/or writer 84 of the option module 80. In such a case, thecard is transported to the card reorienting mechanism 72 which rotatesthe card so that it is aligned with an input into the card reject hopper102, and the card reorienting mechanism 72 then discharges the defectivecard into the card reject hopper 102 using transport rollers on the cardreorienting mechanism 72. Optionally, the card reject hopper 102 can belocated at any other suitable location in the modular print engine 10,and cards to be stored in the card reject hopper 102 can be transportedto the card reject hopper 102 using a suitable transport mechanism.

In one exemplary operation of the modular print engine 10 of FIG. 1, acard can be initially input from the input hopper 62 through the input60. In one embodiment, the card is initially transported along the cardtravel path 68 to the card reorienting mechanism 72, which redirects thecard onto the second card travel path 76 where the card is transportedinto the option module 80. The option module 80 determines whether themagnetic stripe and/or the chip on the card are working correctly, andif they are, data is written onto the magnetic stripe and/or onto thechip. If they are not working correctly, the card can be transportedback along the second card travel path 76 to the card reorientingmechanism 72 which then directs the card into the card reject hopper102. After the data has been written, the card is transported back alongthe second card travel path 76 to the card reorienting mechanism 72which then directs the card back onto the first card travel path 68. Thecard is then transported back toward the front end 52 upstream of theprint engine 74 for printing. The card is then printed on by the printengine 74. After printing, if it is anticipated that the printing causedthe card to bend, the card is transported to the de-bowing mechanism 100which removes the bend in the card. The card is then transported to thecard reorienting mechanism 72 which redirects the card to the third cardtravel path 86. The card is then transported out of the modular printengine 10 and into the lower module 12 through the aligned card opening90 and the slot 26, and to the card reorienting mechanism 30 in thelower module 12. The card reorienting mechanism 30 redirects the cardonto the card transport path 24 where the card is transported to thecard processing mechanism(s) 36. After the card is processed in the cardprocessing mechanism(s) 36, the card can then be output from the lowermodule 12 via the output 38.

In other embodiments, after the card is processed in the card processingmechanism(s) 36, the card can then be redirected back to the cardreorienting mechanism 30 via the card transport path 24, and redirectedout of the lower module 12 and back into the card reorienting mechanism72 of the modular print engine 10. The card reorienting mechanism 72 canreorient the card for transport back along the card travel path 68 andinto the output hopper 66. Alternatively, if the card opening 94 in therear 54 is used, the card can be redirected by the card reorientingmechanism 72 to the fourth card travel path 92 for discharge out thecard opening 94. Alternatively, as discussed further below, the card canbe directed upwardly for discharge out of a card opening in the top ofthe modular print engine 10.

Many other operational sequences of the modular print engine 10 of FIG.1 are possible including, but not limited to, directing the card firstto the lower module 12, and then back into the modular print engine 10for processing by the option module 80 and the print engine 74. Inaddition, the card can be initially printed by the print engine 74 priorto the card being directed to the option module 80 and/or to the lowermodule 12. In addition, the card can be initially directed into theoption module 80, followed by processing in the lower module, followedby printing by the print engine 74.

As illustrated in FIG. 1, the print engine 74 is disposed above the cardtravel path 68. Applicant has discovered that locating the card travelpath 68 below the print engine 74 improves the resulting print processby the print engine 74. For example, card handling is more reliable. Forprint engines that rely upon heat in the printing process, for exampleusing one or more heated transfer rollers in the case of retransferprinting, the improved card handling is believed to result from heatrising upward in a direction away from the card during printing.

As described above, in one embodiment the print engine 74 can beconfigured to perform retransfer printing. Retransfer printing is wellknown in the art. FIG. 2 illustrates an example of the print engine 74configured for retransfer printing. The illustrated retransfer printingconfiguration includes a print side that includes print ribbon supply150 from which a supply of monochrome or multi-color print ribbon 152 issupplied, and a print ribbon take-up 154 that takes-up used print ribbon152. The print ribbon is directed past a print head 156, which in theillustrated example can be stationary, which transfers dye or pigmentink from the print ribbon 152 onto a retransfer film 158. Afterprinting, the used print ribbon 152 is then wound onto the take-up 154.

The retransfer film 158 is supplied from a film supply 160 on aretransfer side, and after retransfer the remaining film is wound onto afilm take-up 162 also on the retransfer side. The retransfer film 158 isdirected past a platen roller 164 positioned opposite the print head 156and which in the illustrated example can be moved toward and away fromthe print head 156 to press the retransfer film 158 and the print ribbon152 between the print head 156 and the platen roller 164 during printingonto the retransfer film 158. The retransfer side can also include acapstan roller 166 that is also movable toward and away from the printside.

Once a desired image is printed onto the retransfer film 158, theretransfer film 158 with the printed image is advanced to a transfersection 168 where the printed image on the retransfer film 158 istransferred onto a surface of the card. The transfer section 168includes a heated transfer roller 170 that is movable toward and awayfrom a fixed platen 172 positioned on the opposite side of the travelpath 68. The heated transfer roller 170 presses the portion of theretransfer film 158 containing the printed image against the surface ofthe card which is backed by the platen 172, with the retransfer film 158and the card then being transported together past the heated transferroller 170 to transfer the layer of the retransfer film 158 containingthe printed image onto the card surface. The remainder of the retransferfilm 158 is then wound onto the film take-up 162.

The specific construction and operation of retransfer printers,including the print ribbon, the retransfer film, printing an image onthe retransfer film, and transferring the printed image onto a surfaceof a card, is well known in the art. One example of retransfer printingis disclosed in U.S. Pat. No. 6,894,710 among many others. U.S. Pat. No.6,894,710 is incorporated herein by reference in its entirety.

Referring now to FIG. 4, another embodiment of a modular print engine200 is illustrated. Elements of the modular print engine 200 that aresimilar in construction and function to corresponding elements in themodular print engine 10 of FIG. 1 are referenced using the samereference numerals. The lower module 12 is not illustrated in FIG. 4,but the modular print engine 200 would be mounted onto a lower module,which can be similar to or different than the lower module 12 in FIG. 1.

In the embodiment in FIG. 4, the second card travel path 76 extends fromthe card reorienting mechanism 72 to a card opening 202 that is formedin the top 56 of the housing 50. An upper expansion module 204 isattached to the top 56 of the housing 50. The upper expansion module 204can be selectively added to and removed from the modular print engine200 to permit alteration in where cards are output.

The upper expansion module 204 includes an input 206 that, when theupper expansion module 204 is correctly mounted on the housing 50, isaligned with the card opening 202 for receiving a card therein. Theupper expansion module 204 further includes a rotatable card reorientingmechanism 208 and an output 210 through which a card can be output fromthe modular print engine in a rearward direction. A card that enters theupper expansion module 204 is received in the card reorienting mechanism208, which redirects the card approximately 90 degrees and outputs thecard through the output 210 aided if necessary by transport rollers 212.The output 210, or a separate output, could be formed at the front ofthe upper expansion module 204 to allow front discharge of cardsseparately from or in addition to outputting cards to the rear throughthe output 210. If the upper expansion module 204 is not used, cards canstill be output at the top 56 of the modular print engine 200 throughthe card opening 202, or the card opening 202 can be closed to preventcard travel therethrough.

Alternatively, instead of outputting cards from the upper expansionmodule 204, the cards can be output from the lower module 12 or throughthe card opening 94 as discussed above in FIG. 1. Or a user may selectto output one or more cards from the upper expansion module 204, whileselecting to output other cards from other locations of the desktop cardprinter. In this manner, the upper expansion module 204 expands thefunctionality of the modular print engine 200 by allowing a user toconfigure and select how cards are output from the modular print engine200.

Referring now to FIG. 5, another embodiment of a modular print engine250 is illustrated. Elements of the modular print engine 250 that aresimilar in construction and function to corresponding elements in themodular print engine 10 of FIG. 1 are referenced using the samereference numerals. The lower module 12 is not illustrated in FIG. 5,but the modular print engine 250 would be mounted onto a lower module,which can be similar to or different than the lower module 12 in FIG. 1.

In the embodiment in FIG. 5, the fourth card travel path 92 is presentthat extends substantially horizontally from the card reorientingmechanism 72 to the card opening 94 formed in the rear 54 of the housing50. A second option, or rear expansion, module 252 is removably attachedto the rear end 54 of the housing 50 that permits a user to change thefunctionality of the modular print engine 250. The second option module252 includes at least one processing mechanism that is configured toperform a processing operation on, for example, a plastic card. Theremovable second option module 252 is one of a plurality of differentremovable second option modules 252. Each second option module 252 isconfigured to be individually and separately removably installed on therear 54 of the housing 50, and each second option module 252 isconfigured to perform a different processing operation on a plastic cardreceived thereby. One second option module 252 can be removed andreplaced with a different second option module 252 to change thefunctionality of the modular print engine 250.

In general, each second option module 252 includes a card opening 254that, when the second option module 252 is correctly mounted on thehousing 50, is aligned with the card opening 94 for receiving a cardtherein. In addition, each second option module 252 includes a housing255 (seen in FIGS. 6A-C) that houses at least one processing mechanismthat is configured to perform a processing operation, for example apersonalization operation, on a plastic card.

FIGS. 6A-6C illustrate different examples of the second option modules252. Many other examples of second option modules 252 are possibleincluding any combinations of the concepts illustrated in FIGS. 6A-C.

In FIG. 6A, the second option module 252 includes a card travel path 256that extends from the card opening 254 substantially in-line with thetravel paths 68 and 92. The travel path 256 can extend to an output 258in the rear of the housing 255 through which cards can be selectivelyoutput. Cards are transported along the travel path 256 by a suitablereversible or non-reversible transport mechanism, such as transportrollers 260. One or more card processing mechanisms 262 are providedalong the travel path 256, for example above the travel path 256, forperforming one or more additional processing operations on the card. Theprocessing mechanism 262 can be, for example, a personalizationmechanism such as a magnetic stripe reader and/or writer or a smart cardreader and/or writer. The processing mechanism 262 can be any one ormore mechanisms that perform one or more processing operations, such aspersonalization or non-personalization operations, on a card. After theprocessing mechanism 262 finishes processing the card, the card can beoutput through the output 258 or transported back into the modular printengine 250.

FIG. 6B illustrates the second option module 252 as being similar to thesecond option module 252 of FIG. 6A, but including a card reorientingmechanism 264 that can reorient a card onto a new travel path 266 up tothe card processing mechanism 262. After processing by the processingmechanism 262, the card can be directed back to the card reorientingmechanism 264, which then directs the card back onto the travel path 256for output through the output 258 or transport back into the modularprint engine 250.

FIG. 6C illustrates the second option module 252 as including the travelpath 256 but no output 258. Instead, the travel path 256 ends at theprocessing mechanism 262. In FIG. 6C, after processing by the processingmechanism 262, the card is transported back into the modular printengine 250.

Referring now to FIG. 7, another embodiment of a modular print engine300 is illustrated. Elements of the modular print engine 300 that aresimilar in construction and function to corresponding elements in themodular print engine 10 of FIG. 1 are referenced using the samereference numerals. For sake of simplicity, the lower module 12 is notillustrated in FIG. 7, but the modular print engine 300 would be mountedonto a lower module, which can be similar to or different than the lowermodule 12 in FIG. 1. In addition, the transport mechanism, such as therollers 70, and the card de-bowing mechanism 100 are not illustrated inFIG. 7 for sake of simplicity, although a transport mechanism would beincluded for transporting a card along the various card travel pathsdescribed below, and the card de-bowing mechanism 100 can optionally beincluded.

In the embodiment illustrated in FIG. 7, the removable option module 80is physically located below the print engine 74. A card travels alongthe card travel path 68 to the card reorienting mechanism 72 which canreorient the card downward along another card travel path 302 thatextends to the card opening 90 in the bottom 58 of the housing 50 thatcommunicates with the lower module 12 (not illustrated in FIG. 7). Asecond card reorienting mechanism 304 is located along the card travelpath 302 that can redirect the card onto a card travel path 306 alongwhich the removable option module 80 is disposed. The option module 80can be removable and replaceable with another, differently configuredoption module 80 as discussed above for FIGS. 1 and 3A-D. The optionmodule 80 in FIG. 7 can have the same configuration and operation as theoption modules 80 described above with respect to FIGS. 1 and 3A-D. Thecard travel path 306 is illustrated as being parallel to the card travelpath 68, although the card travel path 306 can extend at an angle to thecard travel path 68.

In addition, the card reject hopper 102 can be located in the sameposition as shown in FIGS. 1, 4, and 5. Alternatively, as shown in FIG.7, the card reject hopper 102 can be located between the second cardreorienting mechanism 304 and the rear end 54 of the housing 50. Cardsto be rejected can be directed into the card reject hopper 102 by thesecond card reorienting mechanism 304, by the first card reorientingmechanism 72, or by both of the card reorienting mechanisms 72, 304.

The modular print engine 300 can also include a card imaging device 308that is separate from the option module 80 and adjacent to the cardreorienting mechanism 72. The imaging device 308 can be, for example, ascanner that can read a one dimensional bar code on a card surface or acamera that can be used to read a one or two dimensional bar code on acard surface or capture an image of a card surface. In one embodiment,the camera can be arranged to capture one or more images of a cardsurface while the card is held by the card reorienting mechanism 72.

Although not illustrated in FIG. 7, the modular print engine 300 canalso include the card opening 94 in the rear end 54 thereof that leadsto one of the second option modules 252 described above with respect toFIGS. 5 and 6A-C and/or can include the card opening 202 in the top 56that leads to the upper expansion module 204 described above withrespect to FIG. 4.

Referring now to FIG. 8, another embodiment of a modular print engine350 is illustrated. Elements of the modular print engine 350 that aresimilar in construction and function to corresponding elements in themodular print engine 10 of FIG. 1 are referenced using the samereference numerals. For sake of simplicity, the lower module 12 is notillustrated in FIG. 8, but the modular print engine 350 would be mountedonto a lower module, which can be similar to or different than the lowermodule 12 in FIG. 1. In addition, the transport mechanism, such as therollers 70, and the card de-bowing mechanism 100 are not illustrated inFIG. 8 for sake of simplicity, although a transport mechanism would beincluded for transporting a card along the various card travel pathsdescribed below, and the card de-bowing mechanism 100 can optionally beincluded.

In the embodiment illustrated in FIG. 8, the removable option module 80is physically located along the card travel path 68 between the input 60and the card reorienting mechanism 72. In addition, the print engine 74is positioned along a card travel path 352 that extends downwardly fromthe card reorienting mechanism 72 to the card opening 90 in the bottom58 of the housing 50 that communicates with the lower module 12 (notillustrated in FIG. 8). The print engine 74 can be oriented in adirection so that printing on the card occurs along the card travel path352. However, the print engine 74 can be located along other card travelpaths extending from the card reorienting mechanism 72 so that printingoccurs along any other card travel path. In the case of the print engine74 being configured for retransfer printing, the heated transfer roller170 would be located adjacent to the card travel path 352 asillustrated. A card travels along the card travel path 68 to or throughthe option module 80 and then to the card reorienting mechanism 72 whichcan reorient the card and direct the card downward along the card travelpath 352. The option module 80 can be removable and replaceable withanother, differently configured option module 80 as discussed above forFIGS. 1 and 3A-D. The card travel path 352 is illustrated as beingperpendicular to the card travel path 68, although the card travel path352 can extend at an angle to the card travel path 68.

In addition, the card reject hopper 102 can be located in the sameposition as shown in FIGS. 1, 4, and 5. Alternatively, as shown in FIG.8, the card reject hopper 102 can be located adjacent to the cardreorienting mechanism 72 between the card travel path 352 and the rearend 54 of the housing 50. Cards to be rejected can be directed into thecard reject hopper 102 by the card reorienting mechanism 72.

In one embodiment, the modular print engine 350 can also include a cardimaging device 354 that is separate from the option module 80 andadjacent to the card reorienting mechanism 72. The imaging device 354can be, for example, a scanner that can read a one dimensional bar codeon a card surface or a camera that can be used to read a one or twodimensional bar code on a card surface or capture an image of a cardsurface. In one embodiment, the camera can be arranged to capture one ormore images of a card surface while the card is held by the cardreorienting mechanism 72. In another embodiment, the card can be outputfrom the card reorienting mechanism 72 onto a platform structure 355that holds the card while being imaged by the imaging device 354.

In another embodiment, the modular print engine 350 can also include asmart card reader and/or writer 356 that is separate from the optionmodule 80 and is located adjacent to the card reorienting mechanism 72so that the card reorienting mechanism 72 can reorient and direct a cardinto the smart card reader and/or writer 356 for reading and/or writingon an integrated circuit chip (i.e. smart card chip) on the card. Likethe option module 80, the smart card reader and/or writer 356 can alsobe removable and replaceable with a mechanism having differentfunctionality. For example, a contact type smart card reader and/orwriter 356 can be replaced with a contactless type smart card readerand/or writer 356, or the smart card reader and/or writer 356 can bereplaced with a magnetic stripe reader and/or writer or other cardprocessing mechanism.

Although not illustrated in FIG. 8, the modular print engine 350 canalso include the card opening 94 in the rear end 54 thereof that leadsto one of the second option modules 252 described above with respect toFIGS. 5 and 6A-C and/or can include the card opening 202 in the top 56that leads to the upper expansion module 204 described above withrespect to FIG. 4.

All of the individual features and elements in the embodiments in FIGS.1-8 can be used separately from one another or in any combinationstogether.

The examples disclosed in this application are to be considered in allrespects as illustrative and not limitative. The scope of the inventionis indicated by the appended claims rather than by the foregoingdescription; and all changes which come within the meaning and range ofequivalency of the claims are intended to be embraced therein.

The invention claimed is:
 1. A modular print engine useable in a desktoppersonalized plastic card printer, comprising: a housing having a frontend, a rear end, a top and a bottom; a card input at the front end ofthe housing; a card input hopper that is in communication with the cardinput; a card reorienting mechanism in the housing adjacent to the rearend, the card reorienting mechanism is configured to receive a card androtate the card to redirect the card along a desired card travel path; afirst card travel path between the card input and the card reorientingmechanism; a second card travel path extending from the card reorientingmechanism; a print engine disposed along either the first card travelpath or the second card travel path, the print engine is configured toprint on a card; and a removable option module disposed along either thefirst card travel path or the second card travel path, the removableoption module includes at least one processing mechanism that isconfigured to perform a processing operation on a card; wherein the atleast one processing mechanism of the removable option module comprises:a magnetic stripe reader and/or writer configured to read and/or writeto a magnetic stripe of the card; and/or a chip reader and/or writerconfigured to read and/or write to a chip of the card.
 2. The modularprint engine of claim 1, wherein the print engine is disposed along thefirst card travel path and the first card travel path is below the printengine.
 3. The modular print engine of claim 1, wherein the print enginecomprises a retransfer print engine that is configured to performretransfer printing.
 4. The modular print engine of claim 1, furthercomprising a first card opening in the bottom of the housing and a thirdcard travel path extending from the card reorienting mechanism to thefirst card opening.
 5. The modular print engine of claim 4, furthercomprising a second card opening in the rear end of the housing, and afourth card travel path extending from the card reorienting mechanism tothe second card opening.
 6. The modular print engine of claim 5, furthercomprising a second option module attached to the rear end of thehousing and including an input in communication with the second cardopening for receiving a card from the second card opening, and thesecond option module includes at least one processing mechanism that isconfigured to perform a processing operation on a card.
 7. The modularprint engine of claim 4, further comprising a second card opening in thetop of the housing and the second card travel path extending from thecard reorienting mechanism to the second card opening.
 8. The modularprint engine of claim 7, further comprising an expansion module attachedto the top of the housing and including an input in communication withthe second card opening for receiving a card from the second cardopening, the expansion module includes an output through which a cardcan be output from the modular print engine.
 9. The modular print engineof claim 8, wherein the expansion module includes a card reorientingmechanism.
 10. The modular print engine of claim 1, wherein the secondcard travel path extends above the first card travel path.
 11. A modularprint engine useable in a desktop personalized plastic card printer,comprising: a housing having a front end, a rear end, a top and abottom; a card input at the front end of the housing; a card inputhopper that is in communication with the card input; a card reorientingmechanism in the housing adjacent to the rear end, the card reorientingmechanism is configured to receive a card and rotate the card toredirect the card along a desired card travel path; a first card travelpath between the card input and the card reorienting mechanism; a secondcard travel path extending from the card reorienting mechanism; a printengine disposed along either the first card travel path or the secondcard travel path, the print engine is configured to print on a card; anda removable option module disposed along either the first card travelpath or the second card travel path, the removable option moduleincludes at least one processing mechanism that is configured to performa processing operation on a card; wherein the at least one processingmechanism of the removable option module includes at least one of thefollowing: a magnetic stripe reader and/or writer configured to readand/or write to a magnetic stripe of the card; a chip reader and/orwriter configured to read and/or write to a chip of the card; a camerathat is configured to capture an image of the card while the card islocated in the card reorienting mechanism.
 12. A modular print engineuseable in a desktop personalized plastic card printer, comprising: ahousing having a front end, a rear end, a top and a bottom; a card inputat the front end of the housing; a card input hopper that is incommunication with the card input; a card reorienting mechanism in thehousing adjacent to the rear end, the card reorienting mechanism isconfigured to receive a card and rotate the card to redirect the cardalong a desired card travel path; a first card travel path between thecard input and the card reorienting mechanism; a second card travel pathextending from the card reorienting mechanism; a print engine disposedalong either the first card travel path or the second card travel path,the print engine is configured to print on a card; and a removableoption module disposed along either the first card travel path or thesecond card travel path, the removable option module includes at leastone processing mechanism that is configured to perform a processingoperation on a card; wherein the at least one processing mechanism ofthe removable option module comprises a camera that is configured tocapture an image of the card while the card is located in the cardreorienting mechanism.
 13. A desktop personalized plastic card printersystem that personalizes plastic cards, comprising: a housing having afront end, a rear end, a top and a bottom; a card input at the front endof the housing; a card input hopper that is in communication with thecard input; a card reorienting mechanism in the housing adjacent to therear end, the card reorienting mechanism is configured to receive a cardand rotate the card to redirect the card along a desired card travelpath; a first card travel path between the card input and the cardreorienting mechanism; a second card travel path extending from the cardreorienting mechanism; a print engine disposed along either the firstcard travel path or the second card travel path, the print engine isconfigured to print on a card; and a plurality of first option modules,each first option module is configured to be individually, separately,and interchangeably one for the other removably installed in the housingalong either the first card travel path or the second card travel path,and each first option module is configured to perform a differentprocessing operation on a plastic card received thereby.
 14. The desktoppersonalized plastic card printer system of claim 13, further comprisingone or more of: a card opening in the bottom of the housing, and a cardtravel path extending from the card reorienting mechanism to the cardopening in the bottom of the housing; and/or a card opening in the rearend of the housing, and a card travel path extending from the cardreorienting mechanism to the card opening in the rear end of thehousing; and/or a card opening in the top of the housing, and the secondcard travel path extends from the card reorienting mechanism to the cardopening in the top of the housing.
 15. The desktop personalized plasticcard printer system of claim 13, further comprising a plurality ofsecond option modules, each second option module is configured to beindividually, separately, and interchangeably one for the otherremovably attached to the rear end of the housing, each second optionmodule includes an input that is in communication with the card openingin the rear end of the housing when attached to the rear end of thehousing for receiving a card from the card opening in the rear end ofthe housing, and each second option module is configured to perform adifferent processing operation on a card received thereby.
 16. Thedesktop personalized plastic card printer system of claim 13, furthercomprising an expansion module attached to the top of the housing andincluding an input in communication with the card opening in the top ofthe housing for receiving a card from the card opening in the top of thehousing, the expansion module includes an output through which a cardcan be output.
 17. A modular print engine useable in a desktoppersonalized plastic card printer, comprising: a housing having a frontend, a rear end, a top and a bottom; a card input at the front end ofthe housing; a card input hopper that is in communication with the cardinput; a card reorienting mechanism in the housing adjacent to the rearend, the card reorienting mechanism is configured to receive a card androtate the card to redirect the card along a desired card travel path; afirst card travel path between the card input and the card reorientingmechanism; a second card travel path extending from the card reorientingmechanism; a print engine disposed along the first card travel path, theprint engine is configured to print on a card and includes a printribbon; and the first card travel path is below the print engine. 18.The modular print engine of claim 17, further comprising a card openingin the bottom of the housing through which a card can pass from thehousing.
 19. The modular print engine of claim 17, further comprising acard opening in the top of the housing through which a card can passfrom the housing.